Pattern for vertical casting systems



Dec. 23, 1952 w. H. JOHNSON 2,622,289

PATTERN FOR VERTICAL CASTING SYSTEMS Filed May 4, 1950 3 Sheets-Sheet l INVENTOR WILLIAM H. JOHNSON BY W4 ATTORNEYS Dec. 23, 1952 w. H. JOHNSON PATTERN FOR VERTICAL CASTING SYSTEMS 3 Sheets-Sheet 2 Filed May 4, 1950 INVENTOR" WILLIAM H. JOHNSON M a Q Dec. 23, 1952 w. H. JOHNSON PATTERN FOR VERTICAL CASTING SYSTEMS 3 Sheets-Sheet 3 Filed May 4, 1950 R 0 mm EO vs mN H O J H WI LLIAM m m o 4 m MW Patented Dec. 23 1952 OFFICE PATTERN FOR VERTICAL CASTING SYSTEMS William H. Johnson, Washington, D. 0.

Application May 4, 1950, Serial No. 159,910

(Granted under the act of March 3, 1883, as

amended April 30, 1928; 370 0. G. 757) 6 Claims.

This invention relates to improvements in the casting of metals, more particularly to new'systems for the pouring of metal in vertical casting and to pattern plates for the molding of foundry cores which in the set up position in the foundry flask delineateor embody the new pouring systems of the invention.

Vertical casting as commonly carried out in the foundry involves a system including a vertical conduit or sprue with which is connected a series of horizontally arranged conduits, usually two, lying one above the other, called step gates, which lead into the casting cavity. The pouring system, which is located in the foundry flask adjacent the casting cavity, is defined by juxtaposed forms which carry on their opposing faces, a mirror half of the sprue and the step gates. In operation of the system, the metal is poured into the sprue and enters through the first or lowermost step gate into the casting cavity. When the level of the metal in the casting cavity reaches the point of entry of the next higher step gate, flow of the metal from the sprue into the casting cavity takes place through this step gate, also. This is known in the art as sequence flow of the metal into the casting cavity. It hasthe advantages of shortening the pouring time and tending to produce sounder castings. However, with a single known exception based upon a particular metal, experience has shown that sequence flow of the metal in vertical casting systems can be had only with two step gates; no flow or only a dribbling of the metal into the casting cavity being had through the third step gate. In view of the advantages to bederived' therefrom, it is obviously desirable to have a pouring system in which sequence flow of metals, generally can be had through three rather than only two step gates, especially for the founding of the longer castings.

It is, accordingly, an object of the present in!- vention to provide an improved system for the pouring of metals generally in vertical casting in which sequence flow into the casting cavity can be had through three step gates.

,It is a further object of the invention to provide pattern plates from which can be'molded foundry forms which when set up in the foundry flask define the metal pouring systems of the invention. 7

Other objects of the invention Will become apparent from the description which follows:

Briefly stated, I have found that metal generally can be induced to fiow into the casting cavity in sequence through each of three step gates of a 7 V 2 vertical casting system by providing in combination, a vertical conduit or sprue with which is connected in angular relationship a series of three step gates which lead into the casting cavity and which are further characterized by the fact that the second step gate forms a juxtaposed juncture at the sprue with either the first or the third step gate.

In the other aspect of my invention I have provided pattern plates for the new pouring systems from which, in the usualway, can be molded matching foundry forms which in their juxtaposed or operative position in the foundryfiask define or delineate the new pouring systems. These pattern plates carry on a broad face thereof a raised design in half longitudinal section of the new pouring systems, the raised design taking the form of a series of interconnected half round bosses.

The invention will be more fully understood by reference to the following description taken in conjunction with the accompanying drawing in which like parts carry like numerals and in which, T 1

Figure 1 is a perspective view of a pattern plate carrying a raised design fora pouring system in accordance with the invention, 7

Figure 2 is a perspective view of a pattern plate carrying a raised design for a modified pouring system in accordance with the invention, H

Figures 1A and 2A are schematic showings, in operative set up with a casting cavity, of the new pouring systems which form the subject of the pattern plates of Figures 1 and 2,

Figure 3 is a perspective view of a pattern plate carrying a raised design for a further modified pouring system in accordance with the invention,

Figure 4 is a perspective view of a pattern plate carrying a raised design for a still .further modified pouring system in accordance with the invention,

Figures 3A and 4A are schematic showings, in operative set up with a casting cavity, of the new pouring systems which form the subject matter of the match plates of Figures 3 and 4, and,

Figures 5, 6 and '7 are schematic showings, in operative set up with a casting cavity, of other new pouring systems in accordance with the invention.

In construction of the pouring systems according. to the present invention, the first or lowermost step gate is attached to the sprue at an angle to the vertical between about 30 and about the second at an angle to the vertical between about 30 and about and preferably between about 30 and about 60, and the third at an angle to the vertical between about 30 and about 45. Sequence flow of the metal can be had with various angular arrangements of the three step gates provided the angle of attachment thereof to the sprue lies within the aforementioned angle range for each of the step gates. Obviously, in all arrangements of the step gates, the upper one of a pair of step gates in juxtaposed juncture with the sprue is at a lesser angle to the vertical than the lower one.

Illustrative of angular arrangements of the three step gates which can be employed in accordance with my invention forqobtaining sequence flow of the metal in vertical casting are those appearing in the tables below. .In these tables the step gates are numbered 2, 3 and 4 in line with the ascending order of their attachment to the sprue, step gate 2 being the first or lowermost of the series, and the angle of attachment of thestep gate to the sprue is given in degrees to the vertical.

Referring to Figure 1A, step gates 2, 3 and 4 are connected with the usual sprue I and lead into the casting cavity 5 shown in conventionalized form. Step gate 2 is attached to the sprue I at an angle to the vertical of 45, step gate 3 at an angle to the vertical of 30 and step gate 4 at an angle to the vertical of 45. As shown, step gates 2 and 3 are in juxtaposed juncture with the sprue I. The sprue and step gates are of equal diameter.

Figure 2A shows a modified pouring system similar in construction to that shown in Figure 1A, step gates 2 and 3 being in juxtaposed juncture, but difiering therefrom in the angle at which the step gates are attached to the sprue. In this construction, step gate 2 is attached to the sprue I at an angle to the vertical of 45, step gate 3 at an angle to the vertical of 30 and step gate '4 at an angle to the vertical of 30.

Figures 3A and 4A show modified pouring systems similar in construction to that of Figure 1A with the difierence that step gates 3 and 4 are in juxtaposed juncture with the sprue I, and the angle of attachment to the sprue of step gates 2, 3 and 4 is, respectively, 4545-30 to the vertical in the system of Figure 3A and 3060-30 to the vertical in the system of Figure 4A.

Figures 5, 6 and 7 show further modifications of the pouring system of the invention. They are similar in construction to the pouring systems shown in the other views, more particularly to those shown in Figures 3A and 4A, since step gates 3 and 4 are in juxtaposed juncture with sprue I. In Figure 5, the step gates 2, 3 and 4 are shown attached to the sprue I at angles to the vertical of, respectively, 456030, in Figure 6 at angles to the vertical of, respectively, 3090-45 and in Figure '7 at angles to the vertical of, respectively, 304530.

In operation of the pouring systems shown in Figures 1A, 4A and 5, 6 and 7, the metal is poured into the sprue I and initially enters the casting cavity 5 through step gate 2, which is the lowermost of the series. When the level of the metal in the casting cavity 5 has risen to the point of entry of the step gate 3, metal begins to flow into the casting cavity through step gate 3. Like action takes place in respect to step gate 4, metal flowing to the casting cavity therethrough to complete the casting operation in which sequence flow of the metal is had through all three of the step gates.

Figure 1 shows pattern plate 6 provided with a raised design in half longitudinal section of the pouring system of Figure 1A and in Figures 2, 3 and 4 are shown, respectively, similar pattern plates for the pouring systems of Figures 2A, 3A and 4A, respectively. The raised designs onthe pattern plates are constructed of a series of connected half round bosses which are identified with the respective elements of the pouring systems by means of like numerals. Similar pattern plates can be made for the pouring systems shown in Figures 5, 6 and 7. The pattern plates may be made of wood, metal or other suitable material and the raised design provided thereon in known manner.

Since various modifications and changes may be made in the invention without departing from the spirit or the scope thereof, it is not intended that it shall be limited to the herein described specific embodiments thereof but only as is required by the prior art and the appended claims.

The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.

What is claimed is:

l. A pattern plate for the molding of foundry pouring forms, said pattern plate having attached to a broad face thereof a system of half round bosses including a vertical boss to which is attached along one side thereof a series of three angularly disposed bosses each of which has a crosssectional area equal to that of the vertical bos's, said series of three angularly disposed bosses being so arranged that the first of the series is located at the lower terminal of the vertical boss and at an angle to the vertical of between about 30 and 60, the second is located above the first of the series and at an angle to the vertical of between about 30 and and in juxtaposition to one of the other two bosses of the series at the junction of said bosses with the vertical boss, and the third is located, above the second of the series but below the upper terminal of the vertical boss and at an angle to the vertical of between about 30 and 45. 7

2. A pattern plate as defined in claim 1, wherein the second of the series of angularly disposed bosses is located at an angle to the vertical of between about 30 and 60.

3. A pattern plate as defined in claim 2, wherein the second of the series of angularly disposed bosses is in juxtaposition with the third of the series at their junction with the vertical boss.

4. A foundry pattern for the molding of pouring forms, said pattern comprising a system of solid half cylinders having the flat surface thereof lying in the same plane, said system including a vertical half cylinder to which is attached along one side thereof a series of three angularly disposed half cylinders each of which has a cross-sectional area equal to that of the vertical half cylinder, said series of three angularly disposed half cylinders being so arranged that the first of the series is located at the lower terminal of the vertical half cylinder and at an angle to the vertical of between about 30 and 60, the

' second is located above the first of the series and at an angle to the vertical of between about 30 and 90 and in juxtaposition to one of the other two half cylinders of the series at the juncture of said half cylinders with the vertical half cylinder, and the third is located above the second 6 of the series but below the upper terminal of the vertica1 half cylinder and at an angle to the vertical of between about and 5. A foundry pattern as defined in claim 4, wherein the second of the series of angularly disposed half cylinders is located at an angle to the Vertical of between about 30 and 6. A foundry pattern as defined in claim 5, wherein the second of the series of angularly disposed half cylinders is in juxtaposition with the third of the series at their junction with the vertical half cylinder.

' WILLIAM H. JOHNSON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Name Date Arnette Nov. 14, 1950 OTHER REFERENCES Number 

